Modernization of the Mehrum Nord Transmission Network Enhances Supply Reliability

For the modernization of the transmission grid, VESCON Energy was commissioned with the new construction as well as the reconstruction of the 380/220kV substation Mehrum Nord.

By constructing the 380-kilovolt line, VESCON Energy has created a stable infrastructure for efficient energy distribution and transmission, as well as facilitating the increased utilization of renewable energy sources. This groundbreaking project for a more sustainable future was divided into two phases, A and B.

Section A | New 380/220kV substation Mehrum-Nord

In this initial project phase, a state-of-the-art 380/220 kV switchgear with a total of 11 bays was constructed:

• 2 sets of 380 kV transfer bars over 11 bays for increased flexibility.
• 1 x 2-bay 380 kV transverse coupling for optimal connection to other facility components.
• 1 x 380 kV switchable busbar (partially constructed) for distributing energy in various directions.
• 4 x 380 kV line switching bays for controlling power flows in the network.
• 2 x 380 kV combined coupling transformer switching bays, including 380/220/30 kV transformers, to adjust voltage levels and ensure efficient transmission.
• 1 x 380 kV backup switchgear bay for redundancy in the switchgear.
• 1 x 380 kV U-busbar connection bay to link the switchyard components.
• 1 x 380 kV compensation bay to maintain stable network voltage.
• 2 x 220 kV transformer feed-in bays (cable bays) for transformer currents injection.
• 1 x Diesel Emergency Power Generator (EPG, 500 kVA) to ensure supply during power outages.
• 1 x TenneT Operations Building serving as the control and administration center of the substation.

Section B | Extension 220kV- Mehrum

In the second section of the project, the existing 220 kV Mehrum substation was converted and extended:

• 3-fold 220 kV busbar over 6 switchgear bays for efficient power distribution.
• 1 x 2-field 220 kV transverse coupling for connection to other parts of the plant.
• 2 x 220 kV cable panels for feeding transformer currents.
• 2 x 220 kV reserve bays, which do not require any removal work but serve as additional switching facilities.
• 1 x 2-SS connections to the existing plant to optimally integrate the existing systems.
• 1 x Diesel emergency generator (convert existing generator) for reliable emergency power supply.
• 1 x TenneT operations building for operational management of the expanded substation.
• 1 x 30 kV concrete station as auxiliary power supply to ensure the power supply in the substation.
• 4 x control cells for monitoring and control of the plant.

Erol Pamir
Manager VESCON Energy
Phone +49 1525 6898340
erol.pamir@vescon.com

The projekt:

A German automobile manufacturer commissioned VESCON Automation with the conversion of an existing final assembly line for passenger cars as well as the extension of the load capacity in order to be able to manufacture further vehicle types in the future. The conversion involved these three areas:

1. heavy-duty EMS with upstream conveyor belt

2. assembly crosshead final assembly

3. crosshead return transport

A project with many challenges:

• Highly demanding project in terms of technology and deadlines.
• Tight time frame for commissioning in order not to hold up the production process for too long
• Integration of the final assembly of a new vehicle type (e-mobility) into an existing plant
• Due to the ongoing production process, the assembly took place at a different location
• Limited space

Another challenge: the project was implemented during the height of the Corona pandemic and related Corona requirements affected implementation.

Overall, the project spanned a period of over three years.

Our implementation:

Virtual commissioning:
The existing plant was first converted into a virtual model. Specifically, the hardware and the entire PLC programming were imported. Everything was then simulated with the WinMOD software, which shortened development times, eliminated sources of error in good time and minimised commissioning costs.

Hardware design:
At the beginning, the designers familiarised themselves with the complete system. In particular with the power rail bus system, which establishes the connection between the head control and the trolleys. The entire communication of the system runs via this system. The position of each individual vehicle is identified at all times. Through numerous monitors along the line, the exact location of the vehicle can be called up and the feeding of components such as bumpers can be organised.

• Construction of a commissioning line
• Equipment of the running gear
• Planning of the additional EMS cycles into the existing plant
• Replacement of the feed cabinets
• Reconstruction phase
• Commissioning of the plant and support with peripheral tests

PLC programming & commissioning:
In terms of software, this was probably the biggest project ever for VESCON Automation. Programming with the existing software presented the following challenges:

• Only one employee could effectively work on each PLC at a time, which made it difficult to distribute tasks as well as progress over time.
• Converting an existing plant always means familiarising oneself with existing software programming, which was originally built by another manufacturer.

After reviewing the existing software, a model was developed for the VIBN to test the feasibility of the project in advance. In the next step, the plant software had to be adapted for the conversion and the hardware converted. After the conversion phase, the start-up and shift support began, as well as the follow-up and ongoing optimisations until the final acceptance by the customer. 

Conclusion:

An existing plant was converted in such a way that it is now fit and running robustly for the next few years. The plant ran so stably in the first two days after the extension that all production targets were exceeded.

For the renewal and adaptation at the Hardegsen substation (operation with 380 kV and 110 kV), VESCON Energy was commissioned by Avacon Netz GmbH with the entire electrical installation of the 110 kV plant for the project. The major project included the renewal of the:

• Field control technology, control cells and transformer bays
• Double busbars of the bays with busbar earthing
• Zero-busbar

Services provided by VESCON Energy:

For the primary technical construction of the high-voltage stations, the design plans and the provisional planning were further processed together with VESCON Energy. In the secondary technical expansion, the experts carried out cabling work as well as the installation and connection of all control, protection and general plant components such as auxiliary power and transmission technology. VESCON Energy installed a 110 kV switchgear with a double busbar, rebuilt the plant and created the connection to the distribution network of EAM Netz GmbH.

A solution for every scenario:

The biggest challenge in the implementation of the project has been the continuous operation of the existing plant which was already a central junction for the power supply in southern Lower Saxony. The new construction therefore had to take place without any significant interruption of the power supply.

Another challenge was the fact that two construction sites were in operation at the same time in Hardegsen: The 380 kV plant with 14 bays of TenneT and the 110 kV plant with 28 bays for Avacon Netz GmbH. Through careful planning and close communication with the client, the challenge was mastered.

After a total construction period of 3 years, the substation Hardegsen was commissioned by Avacon Netz GmbH and TenneT in December 2019.

Technical project data:

• 110 kV switchgear with 28 bays including double busbar
• 1x 110 kV coupling bays
• 8x 110 kV line bays
• 5x 110 kV transformer bays
• Rebuild own need

For the renewal of the existing 380kV switchgear at the substation Wilster-West, our long-standing client TenneT TSO GmbH has commissioned VESCON Energy with the entire electrical installation for the project. Project targets:

• Expansion of the transformation station for the feed-in of renewable energies
• Receiving and Distribution of the future transmission capacity of NordLink, SuedLink, the West Coastline, the central axis and the offshore connections in the North Sea

Services provided by VESCON Energy:

VESCON Energy initially planned the primary technology and provisional arrangements for the primary technical construction of the high and maximum voltage stations. In the secondary technical expansion, it carried out cabling work as well as the installation and connection of all control, protection and general plant components such as auxiliary power and transmission technology. A 380kV switchgear with a triple busbar, designed for up to 8,000A, was installed. The new switchgear covers an area of 18 hectares, which is the same as 25 football pitches. VESCON Energy rebuilt the plant and created the connection to the distribution network of SH-Netz with two large transformers.

A solution for every scenario:

The biggest challenge in the implementation of the project has been the continuous operation of the existing plant which was already an important north-south junction. The new construction therefore had to take place without any significant interruption of the north-south connections. Consequently, VESCON Energy initially installed several 380kV temporary installations to ensure operations without almost any interruption.

After a total construction period of 4 years, the new substation Wilster-West was commissioned by TenneT at the beginning of October 2020.

Technical project data:

• 380kV switchgear with 31 bays including triple busbar
• 2x 380kV coupling bays
• 8x 380kV line bays
• 2x 380kV cable bays
• 3x 380kV transformer bays
• 2x 380/110/30kV transformers
• 1x 380/20kV transformer
• 4 bays double 110kV busbar

For a developer and producer of high-quality mechatronic components for the automotive industry, our experts at VESCON Systemtechnik developed an automated test bench for their production.

Here, the test items are carried to the individual test stations by robots, OK tested components are provided with a DMC code and placed directly into customer containers. The company's own tracebility and PDA software SO3 Hiberion is used to control as well as store all measured values for complete traceability.

Due to the successful and satisfying handling and functionality VESCON has already been assigned with a new project for our customer - further orders in the field of valve assembly can be expected.

Services provided by VESCON:

• Software engineering PLC
• Construction & Assembly 
• Production data acquisition
• Commissioning
• Service & Training

Christian Jetzinger
Management
Phone +43 3112 36006-0
christian.jetzinger@vescon.com

Our customer GE&PM relies on the project management software SO3 to significantly increase its communication in projects for plant construction and technical planning as well as visualisation.

Due to GE&PM’s international operations, one challenge is communication in project management. Email communication led to overcrowded inboxes and a lack of overview of current project phases and status reports. Project processes were delayed and there was a negative impact on resources, so improvement was needed. An IT system for project work was sought.

In addition to the desire for a solution for the international communication barrier and confusion about document versions, the new solution was preferably supposed to offer a cloud application and at the same time fulfil the requirement that fed-in data of projects be stored in a secure place. GE&PM also sought a tool that would function as a design database.

In addition to its possible application in process engineering, the VESCON software also provides support in other versatile projects - an added value that was an important factor for the cooperation.

SO3 offers the advantage of working directly with intelligent graphics. While in previous GE&PM projects work was done without the use of professional project management tools, SO3 makes it possible to link intelligent 2D and 3D plant layouts with synchronised lists. This provides a data situation from which important information can directly be derived. In this way, typical questions of everyday project processes can be answered quickly in the simplest way, which would otherwise have to be worked out in a time-consuming manner.

Now GE&PM relies on the help of the VESCON software SO3 from the start of the project to the end of commissioning. Thanks to its flexibility, the tool is applied differently in various project phases. At GE&PM, SO3 is employed wherever electrical components are used and teams works together, especially on an international basis. In process engineering, conveyor technology as well as in workplace equipment. Electrical equipment ordering is also handled with SO3.

Another improvement is the simultaneous work in one tool. As a result, all project participants enter their data independently into the database and are always up to date: For GE&PM's customers, this creates a high degree of transparency in the project status. Few additional coordination phone calls are enough because the same, always up-to-date information is available to the entire development team. Communication runs via the SO3 layout. Comments, questions and information can be exchanged via "post-its" in the SO3 layout.

Alexander Isakov
Product manager SO3
so3@vescon.com

For a leading supplier of energy and data transmission in the automotive and industrial sectors, VESCON Systemtechnik implemented an automated assembly line for cable harnessing. 

The system offers the advantage that diesel as well as petrol variants can be processed and tested on an area of just 24 x 8.5 m - within a product-specific cycle time of 16-25 seconds. By linking the innovative assembly process with the production of matching workpiece carriers by means of 3D printing, VESCON Systemtechnik ensures a consistently high quality of the final products and avoids the problems that non-rigid lack cable harnesses can entail due to unwanted deformation. To ensure an ideal assembly, our experts also rely on automated camera testing based on the principles of machine learning (subfield AI).

Services provided by VESCON:

• Introduction of a new assembly concept 
• Software engineering PLC
• Construction & assembly 
• Commissioning
• Service & Training

Christoph Legat
Department Head Sales & Distribution
Phone +43 3112 36006-750
christoph.legat@vescon.com

Our customer is one of Germany's leading chemical companies. In the year 2012 they trusted VESCON with transferring four ABB Freelance 2000 projects into the new process control system ABB 800xA with „High-Performance-HMI“. The task assigned to VESCON was to coordinate the interfaces in close cooperation with LANXESS and ABB and to create new control diagrams in the process control system 800xA:

• 3 graphic images level 1
• 25 graphic images level 2
• 120 graphic images level 3

Services provided by VESCON:

• coordination
• projecting of the process control system ABB 800xA
• FAT / SAT control diagrams

Norbert Happ
Site Manager Cologne
Phone +49 221 1207169-0
norbert.happ@vescon.com

VESCON has been supporting the KW-Kranwerke AG in the fields of hardware construction, project planning and project management since the beginning of 2008.

The KW-Kranwerke AG continues the tradition of the Mannheimer Kranbau (Mannheim crane construction) and is an innovative medium-sized company that offers customized solutions and services. They focus on the supply of grab bridge cranes, gravel excavators, gantry and slewing cranes and specific hoisting solutions. In the German-speaking regions the KW-Kranwerke AG is the market leader when it comes to fully automated grab bridge cranes for waste icineration plants.

The cooperation with VESCON is characterized by openness and a spirit of partnership. Both companies assist each other in the development of new business fields and the search for qualified personnel.

Services provided by VESCON:

• project planning
• electro-technical engineering
• project management
• hardware construction
• EPLAN support

• Roller test bench
• development EPLAN, S7, Visu